Lapwal Kelompok 1 Fix PDF

Laboratory of Minerals and Materials Processing Technology
Institut Teknologi Sepuluh Nopember
ABSTRACT
Metals are one of the groups of elements that are very common in our lives. At present,
most metals are combined with other metals to produce a mixture of metals or we called
alloys. One of most useful metal is Nickel, which he has a corrotion resistance if mixed
with steel then we get Stainless Steel. In this world, There are two varieties of nickel
one in the earth, nickel sulfide ore at the subtropical area and nickel oxide ore at the
tropical area. The nickel oxide ore are mentioned laterite. The reserves of nickel in the
earth are about 61% in the form of laterite and only 40% of world nickel supply is form
laterite. The experiment aim is to make a good aggromerate both physically and
mechanically to feed into the Direct Reduction Furnace. Equipments used this
Compaction tools 1 set, Drying oven 1 set, Crusher 1 set, Screen with 50 mesh standard
size 1 set, Digital scales 1 set, Measuring cup 1 set, Muffle furnace 1 set, Crucible 1
set, Thermocouple 1 set, Blower 1 set and Materials needed in this experiment are:
Lateritic nickel ores 100 g, Wood charcoal 30 g, Sodium Sulphate 30 g, Tapioca 6 g,
Aquades sufficiently Coals 20-70 g, Limestone 10-45 g, LPG sufficiently. Experiment
procedure started with step 1 Briquetting and Drying The procedure of briquetting and
drying process are: Crushing the Lateritic nickel ores and charcoals, Sieving the
Lateritic nickel ores and charcoals using 50 mesh standard sieve, Mixing the sieved
Lateritic nickel ores with wood charcoals and Sodium Sulphate (Na2SO4) with mass
ratio of 100 : 12 : 12 (ore : charcoal : Na2SO4), Mixing tapioca with 100 mL water and
heating in boiling water until slightly thickened, Adding the mixture of Lateritic nickel
ores, wood charcoals, and Na2SO4 to tapioca and stirring until evently distributed,
Forming the mixture into a pillow shape briquette using mold with compacting device
with a pressure of 30 kgf/cm2 (4 pieces), Measuring the mass of briquettes using digital
scale, Measuring the bulk volume of briquettes using the Archimedes principle, Drying
the briquettes at 110°C for 3 hours using the drying oven, Assessing the briquettes from
their visually to see if there are any cracks or not, Measuring the mass of the briquettes
after drying and calculating mass changes before and after drying and comparing the
mass homogeneity between the four briquettes, Measuring the bulk volume of the
briquettes after drying using the Archimedes principle and calculating the pores present
in the briquettes, Testing the briquettes for fall strength using shatter index test.
Briquettes are placed at a height of 2 meters and freely dropping from there to a steel
plate, Measuring the briquettes in size distribution (category 1: size <5 mm, category
2: size 5-10 mm, and category 3: size >10 mm). Step 2 is Direct Reduction , Inserting
the briquettes into the crucible which contains a mixture of coals and limestones.
Placing crucible inside the muffle furnace and preheating to 700°C in 1 hour. Then,
holding at temperature 700°C for 2 hours, Increasing the temperature to 1400°C in 1
Direct Reduced Iron Experiment

Laboratory of Minerals and Materials Processing
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hour. Then, holding at temperature 1400°C for 6 hours, Colling the briquette inside the
muffle furnace for 12 hours, Removing the reduced briquette from muffle furnace,
Weighing the reduced briquette, Calculating the degree of reduction. From the
experiment we get the calculation of the degree of reduction is -1.0694%. The degree
of reduction influences the reaction process. The higher the degree of reduction Oxygen
content, the less oxygen content removed during agglomeration, the more efficient the
process in the Blast Furnace.
Keyword : Metals, Furnace, Nickel, Direct of Reduction.

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CONTENT
ABSTRACT………………………………………………………………………......i
CONTENT…………………………………………………………………………...ii
FIGUREOF CONTENT………………………………………………………..…..iii
TABLE OF CONTENT…………………...………………………………………..iv
CHAPTER I PRELIMINARY
I.1 Background………………………………………………………………………..1
I.2 Problem Formulation……………………………………………………………...2
I.3 Experiment Aims………………………………………………….………………2
BAB II TINJAUAN PUSTAKA
II.1 Direct Reduced Iron……………………………………………………………...3
II.2 Agglomeration……………………………………………………………………7
II.3 Laterite…………………………………………………………………………...9
II.4 Coal………………………………………………………………………............9
II.5 Charcoal...……………………………………………………………………….11
II.6 Limestone………………………………………………………………………..11
II.7 Muffle Furnace…………………………………………………………..............12
II.8 Crucible……………………………………………………………………...…..13
BAB III METHODOLOGY
III.1 Flowchart……………………...………………………………..........................15
III.2 Materials and Equipments...……………………………………………………16
III.3 Experiment Procedure...………………………………………………………..16

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III.4 Calculation………...……………………………………………………………18
BAB IV DATA ANALYSIS AND DISCUSSION
IV.1 Data Analysis…………………………………………………………………...19
IV.2 Discussion………………………………………………………………………21
BAB V CONCLUSSION AND SUGGESTION
V.1 Conclussion……………………………………………………………………...24
V.2 Suggestion……………………………………………………………………….44
REFFERENCE……………………………...…………………………………….....v

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FIGURE OF CONTENT
Figure II.1 Flow sheet of the FASTMET process……………………………………4
Figure II.2 Process of briquetting……………………………………………………8
Figure II.3 Product of briquetting…………………………………………………….8
Figure II.4 Distribution of laterite all over the world………………………………...9
Figure II.5 How coal was formed…………………………………………………...10
Figure II.6 Wood charcoal…………………………………………………………..11
Figure II.7 Limestone……………………………………………………………….12
Figure II.8 Muffle Furnace………………………………………………………….13
Figure II.9 Crucible Furnace………………………………………………………..14
Figure III.1 Flowchart………………………………………………………………15

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TABLE OF CONTENT
Table 2.1 Direct Reduction Process…………………………………………………3
Table 3.1 Limestone Mass…………………………………………………………..17

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CHAPTER I
PRELIMINARY
I.1 Background
Metals are one of the groups of elements that are very common in our lives.
Ranging from office stationery, cooking utensils, electronic equipment, vehicles, to
building materials, all using devices made with metal base materials, example, iron
which is the basic material of steel or alluminium which make the light material or
component. At present, most metals are combined with other metals to produce a
mixture of metals or we called alloys. The metals are mixed so that they can get the
mechanics dan physics properties of alloy metals that are in accordance with human
needs. The metals that we use now are metals that have gone through various processes
so that they are shaped like we use today. From mining to forming into metals that are
useful in our daily lives. All things about metal processing are packaged in one branch
of science called metallurgy.
One of most useful metal is Nickel, which he has a corrotion resistance if mixed
with steel then we get Stainless Steel. In this world, There are two varieties of nickel
one in the earth, nickel sulfide ore at the subtropical area and nickel oxide ore at the
tropical area. The nickel oxide ore are mentioned laterite. The reserves of nickel in the
earth are about 61% in the form of laterite and only 40% of world nickel supply is form
laterite. the most nickel reserves in the world is Australia with amount of 19 million
metric tons. Then Brazil with an estimated nickel reserves reaching 10 million metric
tons, and Russia with estimated reserves reaching 7.6 million metric tons. Its
characteristics are flexible, making nickel at least used in more than 300,000 products.
Starting from the needs of the metal industry, military, transportation, aerospace,
marine, architecture, to development projects. In many of these products, nickel is used
as a complementary material, which is mixed with other types of metal, or as the main
metal. A mixture of nickel with chrome and iron for example, produces stainless steel
which is commonly called stainless steel. About 65 percent of the world's nickel is used
as a mixture of iron to form stainless steel. As we know the ore of the nickel are limonite
and saprolite. In Indonesia, Nickel reserves in Indonesia are predicted to reach 4.5
million metric tons. According to the Ministry of Energy and Mineral Resources
(ESDM), Indonesia's nickel resources are estimated to reach 2,633 million tons of ore,
with reserves of 577 million tons of ore. These resources are spread across Sulawesi,
Kalimantan, Maluku and Papua with an average nickel content of 1.45 percent.the
potential for nickel is found in Sulawesi island (Sorowako), Southeast Kalimantan,
West Kalimantan, Maluku, and Papua. In addition, there are also areas in Obi Island,

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South Halmahera, North Maluku. The nickel found is closely related to peridotite
rocks. Metals not found in the peridotite itself, but as a result of weathering from the
rock. The nickel mineral is garnerit.
The extraction process of nickel used Direct Reduction Method, and the process
is almost same with Direct Reduction Iron Process. The most important process before
the nickel ore going to extraction process is Agglomeration Process where the purpose
of the process is to agglomorate and homogenize size of the ore (with adding coal and
Na2SO4). In this process, it have 2 processes : Briquetting and Drying. The process of
Briquetting is to compress and compact the nickel ore with partial or full controlled in
order to produce a solid body of defined shape and the briquette nickel ore is dryed
used microwave at 110◦C then goes to the Direct Reduction Nickel Process, which put
the briquette to the muffle furnace at 1400◦C (with add Split Stone and Coke).
I.2 Problem Formulation

The formulation of the problem is how to make a good aggromerate both
physically and mechanically to feed into the Direct Reduction Furnace.
I.3 Experiment Aims

The experiment aim is to make a good aggromerate both physically and
mechanically to feed into the Direct Reduction Furnace.

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CHAPTER II
REVIEW OF LITERATURE
II.1 Direct Reduced Iron
DRI or sponge iron refers to porous iron produced by the DR process. The DR
process is a solid-state reaction process (i.e., solid–solid or solid–gas reaction) in which
removable oxygen is removed from the iron oxide, using coal or reformed natural gas
as reductants, below the melting and fusion point of the lump ore or agglomerates of
fine ore. The external shape of the ore remains unchanged. Due to removal of oxygen
(about 27–30% reduction in weight occurs), a honeycombed microstructure develops
suggesting the name Sponge Iron. (i.e., solid porous iron; lumps/pellets with many
voids filled with air). DRI is obtained when iron oxide(generally lump iron ore or
pellets) is reduced to metallic form in solid state. Since there is no melting, the external
shape is retained. Color changes from red to black. The true density ranges from about
3.5 · 103 to 4.4 · 103 kg/m3. The true density of pure iron is 7.8 · 103 kg/m3. Thus,
there is about 45–56% reduction in true volume and this is manifested in the formation
of pores throughout the interior of sponge iron pieces.
Based on the types of reductant used, the DR processes can be broadly classified
into two groups:
1. Using solid reductant, that is, coal-based DR process
2. Using gaseous reductant, that is, gas-based DR process
Table 2. 1 Direct Reduction Process

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II.1.1 Coal-based processes
In coal-based DR processes, noncoking coal is used as reducing agent. In solid

reduction processes, iron oxides together with solid reductant (noncoking coal) are
charged into the reactor. The generation of reducing gas (mainly CO) takes place in the
reduction reactor, and the product has to be separated from excess reductant, ash, and/or
sulfurabsorbing materials (lime, dolomite) by magnetic separation after discharge at
low temperature, which makes product handling more complicated. Because of the
presence of these substances in DRI, hot briquetting and hot feeding are not possible
for coal-based process. Magnetic separator also does not work at high temperatures to
separate the DRI. Coal-based DR processes like SL/RN (1970), ACCAR (1973),
KRUPP (1973), CODIR, and TDR (1975), using rotary kiln as a reactor and coal as a
reductant, have been developed worldwide. India, due to its large reserve of noncoking
coal, has shown keen interest in pursuing these technologies using such coal as a cheap
energy source for highest DRI production in the world. These processes are highly
sensitive to the types of raw materials used.
The following are coal-based processes:
1. Rotary kiln–based processes SL/RN, CODIR, ACCAR, DRC, TDR, SIIL,

OSIL, Jindal
2. Shaft furnace–based processes Kinglor, Metor, NML, Vertical Retort
3. Rotary hearth furnace (RHF)-based processes INMETCO, FASTMET, Comet
The main advantages of coal-based processes are as follows:
1. They do not require high-grade coal that is scarcely available.

2. They use noncoking coal.
3. They can be installed at lower capacity.
4. They can be easily installed at places where small reserves of coal and iron
ore are available.
5. Modules of small-scale operation are available.
Disadvantages of coal-based processes are as follows:
1. Lower economy of scale.

2. High energy consumption (16.0–21.0 GJ/t).
3. Low carbon content in the product (<1.0%).
4. Lower productivity (0.5–0.9 t/m3/day).
5. Hot feeding to the steelmaking furnace and hot briquetting are not possible
due to the presence of residual char and ash in DRI.

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Figure II. 1 Flow sheet of the FASTMET process
II.1.2 Gas-based processes
Reformed natural gas is used as a reducing agent. Iron ore lumps or pellets are
reduced in the solid state and oxygen from iron oxide is removed by a gaseous reducing
agent. Natural gas is reformed at 950C (1223 K), in the presence of catalysts (Ni or
Al2O3), to produce reducing gases CO and H2. The reducing gases H2, CO, or mixture
of H2 and CO, are introduced into the reactor at elevated temperatures [up to 1000C
(1273 K)] and pressure (up to 5 bars). If CH4 is present in the reducing gas, it results
in carburization of the reduced product.The processes based on gaseous reduction are
confined to the areas where natural gas is available in abundance at a reasonable price.
Commercialized processes that use reformed natural gas as reducing agents are Midrex
(1969) and HyL (II–1957, III–1980). The following are gas-based processes:
1. Retort processes HyL I, Hoganas

2. Shaft furnace processes Midrex, HyL III, Plasmared, Armco, Purofer, NSC,
HyL IV
3. Fluidized bed processes FIOR, Finmet, Circored
Gas-based processes have the following advantages:
1. High productivity
2. Lower energy consumption (10.5–14.5 GJ/t)
3. Higher carbon content in the product (>1.0%)
Gas-based processes account for 78.8% of the world’s DRI production; out of that
Midrex alone contributed 63.2% in 2013.

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The gas-based processes offer distinctadvantages over the coal-based processes:
1. Less capital cost: The capital cost per tonne of installed capacity in case of
coal-based plants is 1.8–2 times as high as that of gas-based plants.
2. High productivity: The throughput rates for gas-based DRI plants are much
higher than that of coal-based plants. The productivity of gas-based plants can
be as high as 11 t/m3/day as against merely 0.5–0.9 t/m3/day for coal-based
plants.
3. Better quality: The quality of the DRI produced in terms of metallization and
carbon content is also higher for gas-based plants.
II.1.3 Reaction of Direct Reduction Processes
The reduction of iron ore occurs at 900–1000C (1173–1273 K) in the presence

of coal. Although it is a solid–solid reaction, it takes place via a gas–solid reaction:
3Fe2O3(s) + CO(g) = 2Fe3O4(s) + CO2(g) (2)
Fe3O4(s) + CO(g) = 3FeO(s) + CO2(g) (3)
FeO(s) + CO(g) = Fe(s) + CO2(g) (4)
CO2(g) + C(s) = 2CO(g) (5)
Hence, the overall reaction is
Fe2O3(s) + C(s) = Fe(s) + 3CO(g) (6)
Carburization
3Fe(s) + 2CO(g) = Fe3C(s) + CO2(g) (7)
3Fe(s) + C(s) = Fe3C(s) (8)
Where the reduction is carried out below approximately 1000C (1273 K), the
reducing agents is CO and the DRI produced is porous and have roughly the same size
and shape as the original iron ore or pellets. The metallic iron also absorbs carbon
according to reactions (7) and (8) to form iron carbide (Fe3C).
Reforming of Natural Gas Reformed natural gas is used as a reducing agent. Iron
ore lumps or pellets are reduced in the solid state and oxygen from iron oxide is
removed by a gaseous reducing agent (CO and H2) that takes part in the reduction of
iron oxide. Methane (CH4) is not used directly for the reduction of iron ore because:

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1. The rate of the reaction is very slow

2. Due to high temperatures, decomposition of methane takes place and carbon
soot is formed
CH4(g) = C(s) + 2H2(g) (9)
Hence, methane (CH4) has to be reformed into CO and H2 in the presence of a

catalyst (Ni or Al2O3) at 950C (1223 K). There are four types of reformations:
1. Steam reformation
CH4(g) + H2O(g) = CO(g) + 3H2(g) (10)
2. Oxygen reformation
1
CH4(g) + 2O2(g) = CO(g) + 2H2(g) (11)
3. Carbon dioxide reformation
CH4(g) + CO2(g) = 2CO(g) + 2H2(g) (12)
4. Combination of steam and oxygen reformation
1
2CH4(g) + H2O(g) + 2O2(g) = 2CO(g) + 5H2(g) (13)
Reduction reaction for gaseous reductant Apart from reactions (2) to (4), a
considerable part of reduction occurs due to H2 gas:
3Fe2O3(s) + H2(g) = 2Fe3O4(s) + H2O(g) (14)
Fe3O4(s) + H2(g) = 3FeO(s) + H2O(g) (15)
FeO(s) + H2(g) = Fe(s) + H2O(g) (16)
In gas-based DR process, the reducing agent is a mixture of CO and H2. The

interconversion reaction between CO and H2O takes place according to the following
reaction:
CO(g) + H2O(g) = CO2(g) + H2(g) (17)
This reaction is popularly known as water–gas displacement reaction and occurs

at a temperature below 1000C, due to the unstability of CO gas. The water–gas
displacement reaction becomes less important above 1000C because any water formed
from the reduction of iron ore is rapidly reduced by carbon:
H2O(g) + C(s) = CO(g) + H2(g) (18)
As per the thermodynamic requirements, when a system is in equilibrium, all

parts of the system must be in equilibrium. Therefore, whatever (pCO2 =pCO) ratio is
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in equilibrium with a solid phase must also be in equilibrium with the gaseous phase
[water vapor and hydrogen gas in reaction (17)].
Carburization
3Fe(s) + CO(g) + H2(g) = Fe3C(s) + H2O(g) (19)
3Fe(s) + CH4(g) = Fe3C(s) + 2H2(g) (20)
Most of the previously mentioned reactions are endothermic and hence heat must
be provided for these reactions to occur. So heat transfer plays a very dominant role in
the DRI production processes.
The reduction of iron oxide by carbon monoxide or hydrogen takes place in three
stages at temperature above 567C (840 K):
I II III
Fe2O3 Fe3O4 FeO Fe
Oxygen content 30.1% 27.7% 22.3% 0% (21)
(Dutta.2016.1082-1090)
II. 2 Agglomeration
Agglomeration is a process of size ,enlargement; btiquetteing,, sintering and

pelletising being the three common processes used in the metallurgical industries. The
requirement of particle size for sintering is much coarser (generally upto 10 mm)
against that of pelletising which is generally below 0.1 mm. The briquetting process
can accommodate the size range of both sintering and pelletising. With development
of beneficiation process to treat low grade ores, the particle size of concentrate had
consistently reduced. Thus it becomes necessary to agglomerate the fine concentrates
to make them suitable for subsequent metallurgical operations. Agglomeration plays
more important' role in ferro alloy industry as the costly basic raw material is mostly
obtained in the form of fines generated during mining operation or obtained after
beneficiation. The closer' size range and higher strength of raw materials obtained
during agglomeration improves the performance of arc furnace to a great extent.
Further the ore feed is partly reduced outside the arc furnace, so that the power

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requirement in the arc furnace is much lower and overall economics of the operation is
improved.
Five iron ore agglomeration technologies can be defined: briquetting,

nodulization, extrusion, pelletization and sintering. Sintering and pelletization are the
most important agglomeration technologies, in this way, in the EU-27, 14 countries
operate 34 iron ore sinter plants with 63 iron ore sinter strands, producing in the first
decade of the twenty-first century 130 million tons of sinter annually, on its behalf, 6
pelletization plants produce 27 million tons of pellet annually. Here we are going to
describe all these agglomeration technologies, with special dedication to pelletizing
and sintering as they are the most used worldwide.
1. Briquetting
Briquetting is the simplest agglomeration process. Fine grained iron ore is
pressed into two pockets with the addition of water or some other binder agent
(molasses, starch, or tar pitch) to form briquettes. A traditional application is the
agglomeration of coal, other example is the agglomeration of ultrafine oxidized
dust produced in the ferroalloys industry.
2. Nodulization
Nodulization is a process like sintering as it does not need a binder agent.
The iron ore concentrate is mixed with carbon, and fed into a rotary kiln, where
the material is tumbled at 62 Iron Ores and Iron Oxide Materials high temperature
to form nodules. Reached temperature is enough to soften the ore but not to fuse
it. Problems of the nodules are the considerable differences in composition and
density (they are too dense), and the lack of a well-developed porosity
(permeability) which is of great importance for the operation in the blast furnace.
This process, as briquetting, is mainly used for the recycling of iron ore wastes
in steel plants.
3. Extrusion
Extrusion is a process widely used in the ceramic industry, but it has begun
to be used in the ironmaking and steelmaking industry in the agglomeration of
powders generated in the factories as Basic Oxygen Furnace and Electric Arc
Furnace powders. A certain level of moisture is required, as well as a binder
agent, for instance bentonite or Portland cement. The mixture is sent to the
extrusion machine to obtain the agglomerated product.
4. Pelletization
Pelletization is an agglomeration process of iron ore concentrates with a
granulometry lower than 150 μm and low concentration of impurities. This iron
ore is mixed with water, bentonite (or other organic binders less expensive and
contaminant), and lime and treated in a furnace at temperatures of around
1200_C, with the purpose of obtaining a product of 10–20 mm in diameter with
suitable physical, chemical, and mechanical properties to be fed into the blast
furnace or to the production of DRI (Direct Reduction Iron). Sintering raw mixes
with a high proportion of fines (<150 μm) deteriorates the operation of the
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Dwight-Lloyd sinter machine, and for that reason pelletizing is the best method
for treating this kind of material. The formation of liquid phases, which
agglomerate the iron ore, in pellets is achieved by an external source of energy
(fuel, natural gas or pulverized coal), as opposed to sintering, where liquid phases
are consequence of the combustion of coke breeze.
5. Sintering
Sintering is a thermal process (1300–1400_C) by which a mixture of iron
ore, return fines, recycled products of the iron and steel industry (mill scale, blast
furnace dusts, etc.), slagforming elements, fluxes and coke are agglomerated in
a sinter plant with the purpose of manufacturing a sintered product of a suitable
chemical composition, quality (physically) and Iron Ores and Iron Oxide
Materials granulometry to be fed into the blast furnace, ensuring a homogenous
and stable operation in the blast furnace. This definition proposed in, describes
the sintering process, but prior to sintering there is an important process called
granulation that is deeply reviewed also in. Granulation is the homogenization of
the iron ore mixture in a rotatory drum with 7–8% water having as objective the
obtaining of a pre-agglomerated product, which is then delivered as a layer over
a continuously moving grate or “strand” (Dwight-Lloyd machine) to obtain the
sintered product. This process that takes between 30 and 60 min. (including the
addition of moisture, granulation and feeding to the sintering machine) has a
fundamental role as it ensures an adequate sinter bed permeability and hence
good productivity
(Gonzales.2017.62-65)

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Figure II. 2 Process of briquetting Figure II. 3 Product of briquetting
(Ojaomo.2015.1432)
II.3 Laterite
Laterites are the residual products of chemical weathering of rocks at the surface
of the earth, in which various original or primary minerals unstable in the presence of
water, dissolve or break down and new minerals are formed that are more stable to the
environment. Laterites are important as hosts to economic ore deposits, as the chemical
interactions which together make up the lateritisation process can in certain cases be
very efficient in concentrating some elements. Well-known examples of important
lateritic ore deposits are aluminous bauxite and enriched iron ore deposits, but lesser
known examples include lateritic gold deposits (e.g., Boddington in Western Australia)
(Evans, 1993).
Nickel laterites are the product of lateritisation of Mg-rich or ultramafic rocks

which have primary Ni contents of 0.2-0.4% (Golightly, 1981). Such rocks are
generally dunites, harzburgites and peridotites occurring in ophiolite complexes, and
to a lesser extent komatiites and layered mafic-ultramafic intrusive rocks in cratonic
platform settings (Brand et al, 1998). Lateritisation processes result in the concentration
by factors of 3 to 30 times the nickel and cobalt contents of the parent rock. The
processes, and the character of the resulting laterite, are controlled on regional and local
scales by the dynamic interplay of factors such as climate, topography, tectonics,
primary rock type and structure.
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Figure II. 4 Distribution of laterite all over the world
II.4 Coal
Coal is a combustible black or brownish-black sedimentary rock with a high

amount of carbon and hydrocarbons. Coal is classified as a nonrenewable energy
source because it takes millions of years to form. Coal contains the energy stored by
plants that lived hundreds of millions of years ago in swampy forests.
Layers of dirt and rock covered the plants over millions of years. The resulting
pressure and heat turned the plants into the substance we call coal.

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Figure II. 5 How coal was formed
Coal is classified into four main types, or ranks: anthracite, bituminous,

subbituminous, and lignite. The ranking depends on the types and amounts of carbon
the coal contains and on the amount of heat energy the coal can produce. The rank of
a coal deposit is determined by the amount of pressure and heat that acted on the plants
over time.
1. Anthracite contains 86%–97% carbon and generally has the highest heating
value of all ranks of coal. Anthracite accounted for less than 1% of the coal
mined in the United States in 2017. All of the anthracite mines in the United
States are in northeastern Pennsylvania. Anthracite is mainly used by the
metals industry.
2. Bituminous coal contains 45%–86% carbon. Bituminous coal in the United
States is between 100 million and 300 million years old. Bituminous coal is
the most abundant rank of coal found in the United States, and it accounted
for about 46% of total U.S. coal production in 2017. Bituminous coal is used
to generate electricity and is an important fuel and raw material for making
iron and steel. West Virginia, Illinois, Pennsylvania, Kentucky, and Indiana
were the five main bituminous coal-producing states in 2017, accounting for
74% of total bituminous production.
3. Subbituminous coal typically contains 35%–45% carbon, and it has a lower
heating value than bituminous coal. Most subbituminous coal in the United
States is at least 100 million years old. About 45% of total U.S. coal
production in 2017 was subbituminous and nearly 89% was produced in
Wyoming.
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4. Lignite contains 25%–35% carbon and has the lowest energy content of all
coal ranks. Lignite coal deposits tend to be relatively young and were not
subjected to extreme heat or pressure. Lignite is crumbly and has high
moisture content, which contributes to its low heating value. Lignite
accounted for 9% of total U.S. coal production in 2017, and about 50% was
mined in Texas and 43% in North Dakota. Lignite is mostly used to generate
electricity. A facility in North Dakota also converts lignite to and pipes it to
natural gas consumers in the eastern United States.
(US Energy Information Administration, 1)
II.5 Charcoal
Charcoal is a black residue containing impure carbon produced by removing

water content and volatile components from animals or plants. Charcoal is generally
obtained by heating wood, sugar, bones, and other objects. Charcoal that is black, light,
easily broken, and resembles coal, which consists of 85% to 98% carbon, the rest is ash
or other chemical objects. There is seven types of charcoal can be used:
1. Wood charcoal
2. Sawdust charcoal
3. Rice husk charcoal
4. Coconut shell charcoal
5. Litter charcoal
6. Charcoal briquettes
7. Mahogany skin charcoal
Wood charcoal is charcoal made from wood. Wood charcoal is most widely used
for cooking purposes as described previously. While the use of other wood charcoal is
as a water purifier, use in the health sector, and much more. The wood material used
for wood charcoal is wood that is still healthy, in this case decaying wood.

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II.6 Limestone
Figure II. 6 Wood charcoal
Limestone is a type of carbonate rock which occurs in nature, also called

limestone. The main mineral of limestone is calcite (CaCO3), other minerals are
impurity minerals, usually consists of quartz (SiO2), the carbonate associated with iron
and mineral minerals clays, as well as plant residual organic matter. Calcite minerals
are formed through the process of sedimentation so limestone is also called sedimentary
rock. Calcite mineral with a hexagonal crystal system structure. Besides calcite in
nature, carbonate minerals are also found others are aragonite (CaCO3) which has
chemical composition is the same as calcite but the structure the crystals are different,
namely the orthorhombic system. Aragonit found on shells (oyster shells) and
snails(oolites). Aragonite is metastable, in time old will turn into calcite. Mineral
carbonate others associated with calcite are siderite (FeCO3), anker (Ca2MgFe (CO3)
4), and magnesite (MgCO3), these minerals are generally found in small quantities.
Carbonate minerals are not easily differentiated one of the others because it has
properties almost the same physical, such as specific gravity, color, crystal shape, and
other physical properties. The most common impurity found in carbonate rocks is clay.
Clay minerals, especially kaolinitilit, chlorite, and smectite can be dispersed throughout
rocks or concentrated in thin layers (laminae) in rocks. Besides clays, other impurities
is quartz, which is spread in carbonate rocks in the form of fine grains measuring 1 to
10 microns(microcrystalline quartz) to sandsize quartz. Other impurities are bitumen,
i.e. organic matter, spread in fine form inside carbonate rocks. This organic substance
gives color brown to black on rocks. For some certain uses such as fillers and coatings
the paper containing the bitumen is not desired.

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Limestone drains are easy to construct, use inexpensive and environmentally

benign materials, and operate for extensive periods of time with only periodic
maintenance. As AMD solutions flow through a limestone drain, H+ is consumed by
reaction with calcite in the limestone. At low pH (< ∼6.3) the reaction produces
carbonic acid and at higher pH (> 6.3) bicarbonate ions are produced, as respectively
described by the equations:
CaCO3(calcite) + 2 H+ = Ca2+ + H2CO3 (1)
CaCO3(calcite) + H+ = Ca2+ + HCO3− (2)
As these reactions remove H+, the pH increases, which causes cations to

hydrolyze and release more H+ (latent acidity). Net acidity in AMD is the sum of the
free H+ concentration and the H+ released from latent acidity produced by the
Figure II. 7 Limestone

hydrolysis of Fe2+, Fe3+, Mn2+, and Al3+
II.7 Muffle Furnace
This invention relates to a tunnel type heating furnace provided with an elongated
metallic muffle, and more particularly it relates to a muffle furnace in which pro visions
are made to prevent the deformation or warp of muffle. Various gases are employed as
an atomophere of furnaces for the deoxidation or oxygen free heating of articles in the
furnaces. In order to keep the atmosphere at a high purity, metallic muffles are often

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used. How ever, such muffles which are elongated and extend sometimes as long as 10
m, are apt to warp on account of differences of temperature produced among different
portions thereof and especially between upper and lower portions with the elevation of
temperature at their cyclic first operations and with the repeated intro duction of articles
thereinto. This warp or deformation adversely affects the normal operation of furnaces.
Hence, an object of this invention is to provide a muffle furnace in which the metallic
muffle shall not be deformed, and by which articles in the furnace can be uniformly
heated. It is known for those skilled in this art to control a temperature of metallic
muffles in a heating furnace under a predetermined temperature by means of
programmed heating. This conventional method can not, however, prevent the
deformation of the muffles, because while it can make the muffles be subjected to a
certain temperature as a whole, it can not prevent dif ference of temperatures existing
among different por tions of muffles. Whereas, in this invention, a muffle which is
heated by a plurality of heaters is checked continuously as to its temperature at several
different portions thereof, and the muffle is continuously kept at a predetermined tem
perature or temperatures corresponding to those exist ing at one or more of said several
portions, while the temperatures of other portions are controlled so as to be
substantially equal to said predetermined tem perature(s). It shall be noted that said
predetermined tempera tures can be varied as one desires, whereby the muffle can be
heated to any desired temperature, and that temperatures working at the muffle are
substantially equal at any portion thereof, whereby muffles shall not be deformed,
resulting in the smooth operation and running of a furnace.
( Takahashi R, 2003.)(Pangestu.2018)

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Figure II. 8 Muffle Furnace
II.8 Crucible
Crucibles are a major and varied group of ceramic vessels. They can be defined as
potentially movable reaction vessels in which high-temperature transformations take place, but with no
permanent unidirectional airflow; it is the latter condition that separates them from
furnaces (Rehren 2003). Crucibles have been used for thousands of years all over the world
wher-ever high-temperature processes were carried out; they are thus truly cross-
cultural artefacts. The examples given here all relate to metals, but other materials such
as glass (Bayley 2000; Rehren 1997a) or artificial pigments (Heck, et al. 2003) are also
made or worked using crucibles. Common crucible processes are physical changes
such as melting but a wide range also involves chemical reactions. It is the uses
to which the vessels are put rather than specific material properties or stylistic attributes
tha define them as crucibles; indeed some crucibles were made as domestic pottery
Crucibles had to allow the temperature of their contents to be raised relatively
easily, while also providing thermal insulation to retain the heat and keep the charge or
melt at the desired temperature. The early top-fired vessels therefore had a wide
opening and were relatively shallow, typically not deeper than mouths – to reduce heat
loss through the surface and prevent oxidation of the charge. In these cases the
vitrification is on the outside, mainly on the base. The context of early crucibles,
refractoriness is a relative term, so defining a ceramic as refractory is best done by
comparison with domestic pottery from the same area and period. The technical
ceramic used for a crucible should only be called ‘refractory’ if it is more heat-resistant
than the local domestic wares, either because of the added temper or through choice of

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particular clays. Some crucible processes require more highly refractory ceramics than
others.
Figure II. 9 Crucible Furnace
(Bayley.2007)

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CHAPTER 3
METHODOLOGY
III.1 Flowchart
Start
Literature Study
Materials and equipments Preparations
Crushing Lateritic nickel ores and charcoals
Sieving Lateritic nickel ores and charcoals using 50 mesh siever
Mixing Lateritic nickel ores with wood

charcoals and Sodium Sulphate
Adding Tapioca to the mixture of Lateritic nickel ores
Briquetting
Measuring the bulk volume and mass of pillow briquette
Drying the pillow briquette with oven
Measuring the bulk volume and mass of dried

pillow briquette and calculating the change
Testing briquette for fall strength and measuring size distribution

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Inserting briquette and mixture of coals and limestones to crucible
Heating the briquette in Muffle furnace
Cooling the briquette inside Muffle furnace for 12 hours
Weighting the reduced

briquette
Calculating the degree of reduction
Data analysis
End
Figure III.1 Flowchart
III.2 Materials and Equipments
III.2.1 Equipments
Equipments used in this experiment are:

1. Compaction tools 1 set
2. Drying oven 1 set
3. Crusher 1 set
4. Screen with 50 mesh standard size 1 set
5. Digital scales 1 set
6. Measuring cup 1 set
7. Muffle furnace 1 set
8. Crucible 1 set
9. Thermocouple 1 set

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10. Blower 1 set

III.2.2 Materials
Materials needed in this experiment are:
1. Lateritic nickel ores 100 g

2. Wood charcoal 30 g
3. Sodium Sulphate 30 g
4. Tapioca 6g
5. Aquades sufficiently
6. Coals 20-70 g
7. Limestone 10-45 g
8. LPG sufficiently
III.3 Experiment Procedure
III.3.1 Briquetting and Drying
The procedure of briquetting and drying process are:
1. Crushing the Lateritic nickel ores and charcoals.

2. Sieving the Lateritic nickel ores and charcoals using 50 mesh standard sieve.
3. Mixing the sieved Lateritic nickel ores with wood charcoals and Sodium
Sulphate (Na2SO4) with mass ratio of 100 : 12 : 12 (ore : charcoal : Na2SO4).
4. Mixing tapioca with 100 mL water and heating in boiling water until slightly
thickened.
5. Adding the mixture of Lateritic nickel ores, wood charcoals, and Na2SO4 to
tapioca and stirring until evently distributed.
6. Forming the mixture into a pillow shape briquette using mold with compacting
device with a pressure of 30 kgf/cm2 (4 pieces).
7. Measuring the mass of briquettes using digital scale.
8. Measuring the bulk volume of briquettes using the Archimedes principle.
9. Drying the briquettes at 110°C for 3 hours using the drying oven.
10. Assessing the briquettes from their visually to see if there are any cracks or
not.
11. Measuring the mass of the briquettes after drying and calculating mass
changes before and after drying and comparing the mass homogeneity
between the four briquettes.
12. Measuring the bulk volume of the briquettes after drying using the
Archimedes principle and calculating the pores present in the briquettes.

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13. Testing the briquettes for fall strength using shatter index test. Briquettes are
placed at a height of 2 meters and freely dropping from there to a steel plate.
14. Measuring the briquettes in size distribution (category 1: size <5 mm, category
2: size 5-10 mm, and category 3: size >10 mm).
III.3.2 Direct Reduction
The procedure of direct reduction process are:
1. Inserting the briquettes into the crucible which contains a mixture of coals and
limestones. The limestones is according to the table below:
Table 3.2 Limestone Mass
Group Limestone mass

1 4g
2 6g
3 8g
4 10 g
5 12 g
6 14 g
7 16 g
2. Placing crucible inside the muffle furnace and preheating to 700°C in 1 hour.
Then, holding at temperature 700°C for 2 hours.
3. Increasing the temperature to 1400°C in 1 hour. Then, holding at temperature
1400°C for 6 hours.
4. Colling the briquette inside the muffle furnace for 12 hours.
5. Removing the reduced briquette from muffle furnace.
6. Weighing the reduced briquette.
7. Calculating the degree of reduction.
III.4 Calculation
The briquette volume measurements is done using the Archimedes principle. The
aquades is inserted into a measuring cup up to a size of 50 mL. Then, briquettes are
inserted into a measuring cup which has been filled with distilled water. Once

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incorporated into water, the final volume is measured. The change in volume is
calculated using the equation below:
∆𝑉𝑜𝑙 = 𝑉𝑜𝑙𝑓𝑖𝑛𝑎𝑙 − 𝑉𝑜𝑙𝑖𝑛𝑖𝑡𝑖𝑎𝑙

...................................... (3.1)
Volume change (∆𝑉𝑜𝑙) in mL us briquette volume. Then, the density of briquette
is calculated using equation below:
𝑚𝑏𝑟𝑖𝑞𝑢𝑒𝑡𝑡𝑒
𝜌=
∆𝑉𝑜𝑙 ................................................. (3.2)
Then, for calculating the pores in briquettes, the calculation conducted using below
equation:
%𝑃𝑜𝑟𝑒𝑠 = ∆𝑉𝑜𝑙 − 𝑉𝑜𝑙𝑏𝑟𝑖𝑞𝑢𝑒𝑡𝑡𝑒 𝑎𝑝𝑝𝑟𝑜𝑝𝑟𝑖𝑎𝑡𝑒 𝑡𝑜 𝑡ℎ𝑒 𝑚𝑜𝑙𝑑

.................... (3.3)
The explanation of the heat of combustion of a compound by its degree of
reduction can be roughly verified on the organic fraction of plant biomass through a
multiple regression of heat of combustion (∆𝐻𝑐 in kJ -)g1 versus carbon, hydrogen,
oxygen and nitrogen contents (c’, h’, x’ and n’, respectively, in mol )-g.1 Backwards
multiple regression enabled us to eliminate n’ as a significant explicative variable, as
expected from the final reduction state of nitrogen after combustion (N2):
∆𝐻𝑐 = 109.2 (4 𝑐 ′ + 0.83 ℎ′ − 1.21 𝑥 ′ ) ............................. (3.4)
Using the practical definition of the generalized degree of reduction:
𝛾 ′ = 4𝑐 ′ + ℎ′ − 2𝑥′ .......................................... (3.5)

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CHAPTER 4
DATA ANALYSIS AND DISCUSSION
IV.1 Data Analysis
IV.1.1 Moisture Content of Briquette
Table 4.1 Drying Data
No Mass Before Drying (gram) Mass After Drying (gram)
1 31 25
2 30 24
3 31 25
Moisture content percentage (Mn):

(𝑊𝑤−𝑊𝑑)
𝑀𝑛 = × 100%
𝑊𝑤
......................................(4.1)
Note:
Mn = moisture content (%)
Ww = mass before drying (gram)
Wd = mass after drying (gram)
Calculation:
(𝑊𝑤−𝑊𝑑) (31−25)
1. 𝑀𝑛 = × 100% = × 100% = 19,35%
𝑊𝑤 31
(𝑊𝑤−𝑊𝑑) (30−24)
2. 𝑀𝑛 = × 100% = × 100% = 20%
𝑊𝑤 30
(𝑊𝑤−𝑊𝑑) (31−25)
3. 𝑀𝑛 = × 100% = × 100% = 19,35%
𝑊𝑤 31
IV.1.2 Degree of Reduction of The Process

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Table 4.2 Direct Reduction Data
No. Mass After Mass After Loss On Degree of Information

Drying DRI (gram) Ignition Reduction
(gram) (LOI) (DOR)
1. 24,5 17 44% -1,0694% Metal formed
Degree of reduction calculation:

𝐿𝑜𝑠𝑡 𝑂𝑥𝑦𝑔𝑒𝑛 𝑚𝑎𝑠𝑠
𝐷𝑂𝑅 = × 100% ................................(4.2)
𝐼𝑛𝑖𝑡𝑖𝑎𝑙 𝑂𝑥𝑦𝑔𝑒𝑛 𝑚𝑎𝑠𝑠
𝐼𝑛𝑖𝑡𝑖𝑎𝑙 𝑂𝑥𝑦𝑔𝑒𝑛 𝑚𝑎𝑠𝑠 = 𝑜𝑥𝑦𝑔𝑒𝑛 𝑡ℎ𝑎𝑡 𝑏𝑖𝑛𝑑𝑖𝑛𝑔 𝑖𝑛𝑡𝑜 𝐹𝑒 𝑎𝑛𝑑 𝑁𝑖 𝑖𝑛 𝑜𝑟𝑒𝑠 ............(4.3)
𝑙𝑜𝑠𝑡 𝑜𝑥𝑦𝑔𝑒𝑛 𝑚𝑎𝑠𝑠 = 𝑊𝑑 − (𝐿𝑂𝐼 × 𝑊𝑑) − 𝑊𝑛 ............(4.4)
Note:
Wd = mass after drying (gram)
LOI = los ton ignition
Wn = mass after DRI (gram)
Calculation:
 Initial oxygen mass
Known: - % wt Fe2O3 = 38,84%

 % wt NiO = 2,03%
m Fe2 O3 = %wt Fe2 O3 × m briquette = 38,84% × 24,5 =

9,5158 gram
mFe2 O3 9,5158 gram
n Fe2 O3 = = gram = 0,0595 mol
mrFe2 O3 160
mol

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m NiO = %wt NiO × m briquette = 2,03% × 24,5 = 0,49735gram

m NiO 0,49735 gram
n NiO = = gram = 0,0066 mol
mrNiO 75
mol
Fe2O3 2 Fe + 1,5 O2
0,0595 mol 0,119 mol 0,08925 mol
m O2 = n O2 × mr O2 = 32 × 0,08925 = 2,856 gram
NiO Ni + O
0,0066 mol 0,0066 mol 0,0066 mol
m O2 = n O2 × mr O2 = 32 × 0,0066 = 0,2112 gram
initial oxygen mass = 0,2112 + 2,856 = 3,0672 gram
 Lost oxygen mass

lost oxygen mass = Wd − (LOI × Wd) − Wn
= 24,5 − (44% × 24,5) − 17
lost oxygen mass = -3,28 gram
 Degree of Reduction (DOR)
Lost Oxygen mass −3,28

DOR = × 100% = × 100% = −1,0694%
Initial Oxygen mass 3,0672

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IV.2 Discussion
Direct Reduction Process is one of the extraction methods to extract metal from an
oxide ore to the pure metal. The definition of direct reduction process is the process of
removing (reduction) oxygen content from an oxide ore that is done in the solid state,
i.e. without melting process, as in the blast furnace. The reducing agents usually are
carbon monoxide and hydrogen, which comes from reformed natural gas, syngas or
coal. The oxide ore which used mostly in pellet and/or lumpy form. The aim of this
experiment is to make a good agglomerate both physically and mechanically to feed
into the Direct Reduction Furnace, and to conduct a direct nickel lateritic reduction
process to increase the nickel content. The equipment used in this experiment is
compaction tools, drying oven, crusher, screen with 50 mesh standard size, digital
scales, measuring cup, muffle furnace, crucible, thermocouple and blower. Materials
used in this experiment is 100g lateritic nickel ore, 30g wood charcoal, 30g Na2SO4
powder, 6g tapioca, aquadest, 1-4 pieces of nickel briquettes, 20-70g coals, 16g
limestone, and LPG. The experiments are consist of 2 processes, Briquetting process
and Direction Reduction process. For the briquetting process, the experiment
procedures are beginning with crushing lateritic nickel ores and charcoals using
crusher, and then mixing tapioca with 100 mL water and heating it in boiling water
until slightly thickened. After that, the mixture of the lateritic nickel ore, wood
charcoal, and Na2SO4 are added with tapioca qand stirred until evenly distributed. The
next step is forming the mixture into a pillow briquette using a mold, and measuring it
mass using a digital scale. The briquettes which have been compacted are then dried at
110oC for 3 hours using the drying oven. And after drying has been done, the briquettes
mass are measured again on digital scales. Then calculated the mass which changes
and compared to know the mass homogeneity between the 3 briquettes. For the direct
reduction process, the experiment procedures are beginning with inserting one
briquette into the crucible and then adding a mixture of coal and limestone until it
reaches a height of 3 cm from the briquette, and then it is repeated with the other two
briquette, the required limestone mass is 16 g. Then the crucible is placed in a Muffle
Furnace and preheated to 700oC for 60 minutes. Then, it was held at a stemperature of
700oC for 2 hours. After that, the temperature was increased to 1400oC in 60 minutes.
Then, it was held at a temperature of 1400oC for 6 hours. After all of that ha been done,
the briquettes are cooled inside the Muffle-Furnace for 12 hours. The reduced
briquettes are then removed from Muffle-Furnace and weighed to calculate the degree
of reduction of the direct reduction process that has been done.

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The briquettes produced before the drying process have initial weight of each are 31g,
30g, and 31g. Following the drying process, the final mass is acquired, the weight of
each sample is 25g, 24g and 25g. After that, the percentage of moisture content in the
briquettes is calculated by dividing the result of subtracting the initial mass with the
mass after drying by the initial mass, and then multiplied by 100%. From the
calculations, the first sample has a moisture content percentage of 19.35%, the second
sample has a moisture content percentage of 20%, and the last sample has a moisture
content percentage of 19,35%. The difference in mass from before and after the drying
is due to the heating, the gasses inside the briquette is evaporated, hence the total mass
of the briquette is decreased.
The DRI process obtained mass after being dried at 24.5 grams. While the mass after
DRI is 17 grams with a percentage of LOI of 44%. From this data, we can calculate the
initial oxygen mass and loss oxygen mass. For the initial oxygen mass obtained at
3,0672 grams, while the loss oxygen mass was obtained at -3.28 grams. So, based on
equation (4.2) obtained percent DOR of -1,0694%. during the direct reduction process,
the nickel briquette is reduced where it aims to purify nickel and eliminate useless
concentrations. At the time of combustion in the muffle furnace there is a reduction
process that removes Na2SO4 and charcoal from briquette nickel due to heating at high
temperatures and long enough time, so that the process produces pure nickel but the
mass decreases. The results are in the form of a minus due to the occurrence of errors
during lab work. The error was due to an error and the inaccuracy of mass calculations
before the furnace.
From the experiment results, the purpose of direct reduction nickel process are to
increase metal purity and removing the oxygen content. The metal purity increasing is
influenced by reducing agent, reducing temperature, and reducing time which prove
from the cite, The reduction temperature had an obvious influence on the conversion
percentage of the total nickel to metallic nickel, as the αNi increased with an increase
in the reduction temperature. The lowest αNi was 27% at a temperature of 500◦C, and
the highest aNi was 84% at a temperature of 1000 ◦C. The activation of mineral
aggregates and the molecular motion of the reactive gas increased, the reaction velocity
increased and the reaction time decreased with an increase in the reduction temperature
(Bo Li, 2011). The conversion percentage increased with an increase in the reduction
time but decreased slowly as the time increased above 80 min. The maximal αNi was
approximately 80% when the reduction time was 80 min. This peak in the conversion
percentage may be attributed to the reductant being consumed gradually with an
increasing reduction time, the CO2 concentration increasing with an increase in the
reduction time, and the boundary of the gas–solid reaction filling with CO2 gas,
inhibiting the progress of the reduction reaction. (Bo Li, 2011)

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CHAPTER V
CONCLUSION AND SUGGESTION
V.I Conclusion
Based on the experiment that we have done from subject Extractive Metallurgy
and Refining Process, there are some conclusion such as:
1. The briquetting process are:

a) Crushing the materials
b) Sieving with 50 mesh siever
c) Mixing the materials together
d) Forming the mixture into a pillow shape briquette
e) Compacting using a device with a pressure of 30 kgf/cm2
f) Drying at 110°C for 3 hours
2. The briquettes made process result is so depend on the every step that involved
in the process, such as the drying process, the moisture content, pressing and
etc. From the experiment we get the calculation of the moisture content
percentage for briquet 1 is 19.35%, briquet 2 is 20%, and briquet 3 is 19.35%.
The mechanical properties of the briquet most commonly affected by the form
of briquette. More homogeneous the briquette, the btter compaction and density
formed. Therefore homogeneity can increase combustion efficiency so that the
energy does not wasted.
3. The carbothermic reduction process are:
a) Placing the briquettes inside the muffle furnace
b) Preheating to 700⁰C in 60 minutes, then holding for 2 hours
c) Increasing to temperature of 1400⁰C in 60 minutes, then holding for 6
hours
d) Cooling for 12 hours inside the Muffle Furnace
e) Measuring the weight of reduction briquette, then calculate the degree
of reduction
4. From the experiment we get the calculation of the degree of reduction is
-1.0694%. The degree of reduction influences the reaction process. The higher
the degree of reduction, the more oxygen is bound in the briquette that is

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released. Oxygen content, the less oxygen content removed during

agglomeration, the more efficient the process in the Blast Furnace.
V.2 Suggestion
Based on the experiment that we have done from subject Extractive Metallurgy
and Refining Process, there are some conclusion such as:
1. Provide more siever so we can sieve the materials efficient without waiting
other friend
2. Always check the temperature so the equipment we use does not break or
melted cause of the high temperature
3. Calculate and measure the component precisely to minimize error

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Laboratory of Minerals and Materials Processing Technology

Institut Teknologi Sepuluh Nopember

Direct Reduced Iron Experiment

Keyword : Metals, Furnace, Nickel, Direct of Reduction.

Direct Reduced Iron Experiment

I.2 Problem Formulation……………………………………………………………...2

I.3 Experiment Aims………………………………………………….………………2

BAB II TINJAUAN PUSTAKA

II.1 Direct Reduced Iron……………………………………………………………...3

II.7 Muffle Furnace…………………………………………………………..............12

BAB III METHODOLOGY

III.2 Materials and Equipments...……………………………………………………16

III.3 Experiment Procedure...………………………………………………………..16

Direct Reduced Iron Experiment

BAB IV DATA ANALYSIS AND DISCUSSION

IV.1 Data Analysis…………………………………………………………………...19

BAB V CONCLUSSION AND SUGGESTION

Direct Reduced Iron Experiment

Figure II.1 Flow sheet of the FASTMET process……………………………………4

Figure II.2 Process of briquetting……………………………………………………8

Figure II.3 Product of briquetting…………………………………………………….8

Figure II.4 Distribution of laterite all over the world………………………………...9

Figure II.5 How coal was formed…………………………………………………...10

Figure II.6 Wood charcoal…………………………………………………………..11

Figure II.7 Limestone……………………………………………………………….12

Figure II.8 Muffle Furnace………………………………………………………….13

Figure II.9 Crucible Furnace………………………………………………………..14

Figure III.1 Flowchart………………………………………………………………15

Direct Reduced Iron Experiment

Table 2.1 Direct Reduction Process…………………………………………………3

Table 3.1 Limestone Mass…………………………………………………………..17

Direct Reduced Iron Experiment

Direct Reduced Iron Experiment

I.2 Problem Formulation

I.3 Experiment Aims

Direct Reduced Iron Experiment

II.1 Direct Reduced Iron

1. Using solid reductant, that is, coal-based DR process

2. Using gaseous reductant, that is, gas-based DR process

Table 2. 1 Direct Reduction Process

Direct Reduced Iron Experiment

II.1.1 Coal-based processes

In coal-based DR processes, noncoking coal is used as reducing agent. In solid

The following are coal-based processes:

1. Rotary kiln–based processes SL/RN, CODIR, ACCAR, DRC, TDR, SIIL,

1. They do not require high-grade coal that is scarcely available.

1. Lower economy of scale.

Direct Reduced Iron Experiment

Figure II. 1 Flow sheet of the FASTMET process

II.1.2 Gas-based processes

1. Retort processes HyL I, Hoganas

Direct Reduced Iron Experiment

The gas-based processes offer distinctadvantages over the coal-based processes:

The reduction of iron ore occurs at 900–1000C (1173–1273 K) in the presence

Fe3O4(s) + CO(g) = 3FeO(s) + CO2(g) (3)

FeO(s) + CO(g) = Fe(s) + CO2(g) (4)

CO2(g) + C(s) = 2CO(g) (5)

Hence, the overall reaction is

Fe2O3(s) + C(s) = Fe(s) + 3CO(g) (6)

3Fe(s) + 2CO(g) = Fe3C(s) + CO2(g) (7)

3Fe(s) + C(s) = Fe3C(s) (8)

Direct Reduced Iron Experiment

1. The rate of the reaction is very slow